Soyer BMK-10i User manual

Operating Instructions
Stud Welding Device
BMK-10i
GB: English Version
Read these operating instructions before starting any work!
Doc.ID: P00259
Date of issue: 08.2017
www.soyer.com

Operating manual Soyer Bolzenschweißtechnik 3
We recommend registering the device numbers here so they can be quickly
accessed if service is needed.
Device
Type
Serial number
Stud welding device
BMK-10i
Stud welding gun
PH-9 SRM12
Stud welding gun
PH-9 SRM12 +G
Stud welding gun
PH-3N SRM
Operating manual
Document no.: P00259, 08-2017, translation of the original German manual
(P00159)
All information in this document is the property of Heinz Soyer
Bolzenschweißtechnik GmbH.
Revision status
Document
Created / modified
Editor
Date
Original
Created
MS/IS
08.2017

4 Operating manual Soyer Bolzenschweißtechnik
Contents
belo
1General information.............................................................................................................. 6
1.1 Validity of the operating manual............................................................................................. 6
1.2 Registered trademarks........................................................................................................... 6
1.3 Abbreviations and definitions................................................................................................. 7
1.4 Declarations of conformity...................................................................................................... 7
1.5 Manufacturer.......................................................................................................................... 9
1.6 Instruction, training................................................................................................................. 9
1.7 Standards and directives........................................................................................................ 9
2Important safety instructions............................................................................................. 10
2.1 Safety alerts used ................................................................................................................ 10
2.2 General safety instructions................................................................................................... 11
2.3 Safety instructions for the working method.......................................................................... 14
2.4 Personal protection equipment ............................................................................................ 15
2.5 Intended use of the stud welding device.............................................................................. 16
2.5.1 Incorrect use.................................................................................................................... 16
2.6 Intended use of the stud welding guns ................................................................................ 16
2.6.1 Incorrect use.................................................................................................................... 17
2.7 Operating company prerequisites........................................................................................ 17
2.7.1 Prerequisites for personnel.............................................................................................. 17
3Transport.............................................................................................................................. 19
4Storage, shutdown.............................................................................................................. 19
5Disposal ............................................................................................................................... 19
6Description of the BMK-10i stud welding device............................................................. 20
6.1 Type designation.................................................................................................................. 20
6.2 Working method................................................................................................................... 20
6.2.1 Stud welding with SRM technology®................................................................................ 21
6.2.2 Drawn arc stud welding technology with shielding gas ................................................... 22
6.3 Overview of the controls....................................................................................................... 23
6.3.1 Display and setting area .................................................................................................. 25
6.4 Technical data of the BMK-10i stud welding device ............................................................ 26
6.5 Permitted stud welding guns................................................................................................ 27
6.6 Cleaning the stud welding device ........................................................................................ 28
7Description of the SRM stud chuck................................................................................... 29
7.1 Setting the SRM stud chuck................................................................................................. 29
8Description of the PH-9 SRM12 stud welding gun ............................................................ 31
8.1 Technical data of the PH-9 SRM12 stud welding gun .......................................................... 32
8.2 Installing the SRM stud chuck in PH-9 SRM12 ..................................................................... 33
8.3 Replacing the SRM12 support tube insert with PH-9 SRM12 ................................................ 35
8.4 Cleaning the welding gun..................................................................................................... 36
9Description of the PH-9 SRM12+G weld gun..................................................................... 37
9.1 Technical data of the PH-9 SRM12+G stud welding gun...................................................... 39

Operating manual Soyer Bolzenschweißtechnik 5
9.2 Operation of the PH-9 SRM12+G.......................................................................................... 39
9.2.1 Safety check .................................................................................................................... 39
9.2.2 Welding with the PH-9 SRM12+G..................................................................................... 40
9.3 Installing the SRM stud chuck for the PH-9 SRM12+G......................................................... 41
9.4 Replacing the SRM12 support tube insert with the PH-9 SRM12+G ..................................... 43
9.5 Cleaning the stud welding gun............................................................................................. 45
10 Description of the PH-3N SRM stud welding gun............................................................ 46
10.1 Technical data of the PH-3N SRM stud welding gun........................................................... 47
10.2 Installing the SRM stud chuck with PH-3N SRM ................................................................. 48
10.3 Cleaning the welding gun..................................................................................................... 50
11 Setup and connection......................................................................................................... 51
11.1 Requirements for the installation location............................................................................ 51
11.2 Connection of the stud welding device and the stud welding guns ..................................... 52
11.2.1 Mains connection......................................................................................................... 52
11.2.2 Connecting the earth cable ......................................................................................... 52
11.2.3 Connecting the stud welding gun ................................................................................ 53
11.2.4 Connecting the shielding gas supply........................................................................... 53
12 Settings ................................................................................................................................ 57
12.1 Setting the welding parameters ........................................................................................... 57
12.1.1 Help tables for device setting ...................................................................................... 58
12.1.2 Setting the welding current and the welding time........................................................ 59
12.1.3 Setting/deactivating the SRM current.......................................................................... 60
12.1.4 Setting the gas preflow time........................................................................................ 61
12.1.5 Setting the lift time (height of lift) in the "Setup" mode................................................ 62
12.1.6 Notes on the PH-9 SRM12+G welding gun.................................................................. 64
13 Welding operation............................................................................................................... 65
13.1 Carrying out welding ............................................................................................................ 65
13.2 Notes on checking the quality of the weld............................................................................ 67
13.2.1 Visual inspection.......................................................................................................... 67
13.3 Switching off the device ....................................................................................................... 68
13.4 Weld defects and their causes............................................................................................. 69
14 Maintenance and repair...................................................................................................... 73
15 Service.................................................................................................................................. 73
16 Warranty conditions ........................................................................................................... 73

1 General information
This operating manual contains important information and requirements for operating
the devices. Keep the operating manual in a readily accessible location close to the
devices.
The term 'Devices' in the operating manual refers to the stud welding device and the
stud welding gun.
Carefully read through the operating manual and the other documents contained in the
technical documentation. In particular, comply with the safety instructions which are
intended to help you recognise any residual risks and prevent hazards.
The drawings and diagrams in this operating manual help illustrate the content and may
vary slightly from the actual equipment.
The manufacturer reserves the right to make technical changes.
1.1 Validity of the operating manual
This operating manual applies to the following devices:
Stud welding device BMK-10i
Stud welding guns PH-9 SRM12
PH-9 SRM12+G
PH-3N SRM
1.2 Registered trademarks
The following terms in this manual are marked with registered trademarks:
SRM®: SRM stands for magnetic field stud welding and refers to stud welding
in a radially symmetrical magnetic field.
SOYER®: Developments/technologies of Soyer GmbH.

Operating manual Soyer Bolzenschweißtechnik 7
1.3 Abbreviations and definitions
Essential abbreviations or designations in this manual:
HZ-1 threaded studs: SOYER® universal studs with centring tip
MF threaded studs: SOYER® threaded studs with a reduced flange
diameter (MF stands for mini flange).
1.4 Declarations of conformity
The devices are built according to the generally accepted codes of practice.
Please note that significant modifications to the device can void the
declaration of conformity.
In addition, the manufacturer warranty coverage may be rendered invalid.

8 Operating manual Soyer Bolzenschweißtechnik
Stud welding device
Heinz Soyer Bolzenschweißtechnik GmbH
Inninger Straße 14
82237 Wörthsee
CE Declaration of Conformity
We herewith declare that the machine described in the following and the version
available on the market correspond in design and construction to the safety and health
requirements of the listed guidelines and standards. Any unauthorised modification to
this machine automatically annuls this declaration.
Designation of machine : Stud welding device
Machine type : BMK-10i
Machine no. : ______________________
Applicable EU directives : RoHS Directive (2011/65/EU)
Low Voltage Directive (2014/35/EU)
EMC Directive (2014/30/EU)
Applied harmonised : EN 60 974-1:2012
standards, in particular EN 60 974-10:2008
Applied national standards : DGUV Regulation 1
Date : 21 July 2017
Producer’s signature : ____________________
Signer’s function : Managing Director

Operating manual Soyer Bolzenschweißtechnik 9
1.5 Manufacturer
The manufacturer of the devices is:
Heinz Soyer Bolzenschweißtechnik GmbH
Inninger Straße 14
82237 Wörthsee
Tel.: [phone]
Fax: [phone]
Mail: [email protected]
Web: www.soyer.de, www.soyer.com
1.6 Instruction, training
SOYER® offers optional and individual instruction in the operation of the devices.
SOYER® also offers training for customer-specific use of the devices.
Information about the scope and costs of instruction and training can be obtained from
Soyer GmbH.
1.7 Standards and directives
The following standards (among others) must be observed for carrying out stud welding
work and for the qualification of personnel:
DIN EN ISO 14555 Welding - Arc stud welding of metallic materials
DIN EN ISO 14732 Welding personnel - Qualification testing of welding operators and
weld setters for mechanized and automatic welding of metallic materials
DIN EN 60974-9 Arc welding equipment - Installation and use
DVS data sheet 0904 Practical tips - Arc stud welding

10 Operating manual Soyer Bolzenschweißtechnik
2 Important safety instructions
Read the following chapter carefully and follow the safety instructions. If you are
uncertain or an instruction cannot be followed, please contact the manufacturer.
The devices have been built according to the generally accepted codes of practice and
in compliance with, and application of, the usual and established safety requirements.
To achieve the maximum possible safety, it is essential that all of the safety instructions
in this operating manual are heeded and followed.
2.1 Safety alerts used
Warning signs are used in this document, depending on the potential danger of the
situation.
Safety and information symbols used in this manual
This safety alert indicates an imminently hazardous
situation which will result in serious injury or death.
This safety alert indicates a potentially dangerous
situation which could result in serious physical injury or
death.
This safety alert indicates a potentially hazardous
situation which could result in minor or moderate injury.
This alert, without the triangle, is also used for
potentially hazardous situations which will result in
property damage.
Additional information indicating danger from electric
current. The additional information is used in
conjunction with a warning sign.
Additional information on the risk of burns. The
additional information is used in conjunction with a
warning sign.
Do not touch the surface of the housing, danger of
electrocution.
Do not touch or open, danger for unauthorised persons.
Danger for persons with a heart pacemaker or other
medical implants.
The info sign is not a safety alert. It indicates important
and useful information on the subject.

Operating manual Soyer Bolzenschweißtechnik 11
Safety instructions on the device
There may be warning stickers on the devices as additional warnings of danger. The
warning stickers are affixed by the manufacturer and must not be removed. If a warning
sticker is damaged and thus illegible, a new warning sticker must be affixed
immediately.
The warning stickers must be obtained from the manufacturer.
2.2 General safety instructions
Danger due to electric current, general information
When working on current-carrying components, there is a danger to life from
Work on electrical or electronic modules may only be carried out by
electrotechnically qualified personnel and carried out in line with the currently
applicable electrotechnical regulations.
Protection equipment must not be manipulated or disabled. Protection
equipment includes, for example, the housing and housing cover, fuses and
device switches.
If protection devices have to be removed for maintenance work, the device
must only be switched on again when all protection devices are mounted
again and their functionality has been checked.
Starting the device with defective protection equipment is not allowed. Repair
or replace faulty protective equipment immediately. Unwanted operation by
a third party must be prevented.

12 Operating manual Soyer Bolzenschweißtechnik
Danger from electric current during maintenance and repair
When working on current-carrying components, there is a danger to life from electric
current.
Work on electrical or electronic components must only be carried out by
electrical specialists from Soyer Bolzenschweißtechnik.
Before working on the stud welding device, the mains switch of the device
must be switched off and the mains plug of the stud welding device
disconnected.
Before working on the stud welding gun, the supply cable to the stud welding
device must be disconnected.
If protection devices have to be removed for maintenance work, the device
must only be switched on again when all protection devices are mounted
again and their functionality has been checked.
Danger from magnetic fields
Strong magnetic fields occur in the area of the device, which may affect the
operation of medical aids, causing a danger to life.
Persons with electrical medical aids (such as pacemakers) must keep away
from the devices.
The operating personnel must ensure that persons with medical aids keep
away from the devices.
Danger of explosion from an inappropriate installation location in explosive
atmospheres
The device is not designed for use in explosive zones.
The device may not be installed and operated in explosive atmospheres.

Operating manual Soyer Bolzenschweißtechnik 13
Danger of burns due to hot surfaces
Through the welding process, the workpieces and some parts of the welding gun
become so hot that touching them can lead to burns.
Always use personal protective equipment.
Before beginning work on hot parts of the device, check that they have
cooled down.
Do not hold the gun tight in the welding area.
Danger of burns from hot welding spatter
Dangerous welding spatter can occur during the welding process.
Always use personal protective equipment.
Fire hazards from hot welding spatter
Welding spatter or hot workpieces occurring due to the welding process can result in
fire hazards.
Do not store any inflammable and combustible materials in the welding area.

14 Operating manual Soyer Bolzenschweißtechnik
2.3 Safety instructions for the working method
Hazards due to incorrect working method
Hazards for operators and third parties can arise due to an incorrect working method.
Ensure sufficient stability and a dry installation location for the stud welding
device.
Make sure you do not knock over the stud welding device or pull it down from
its position with the gun cables.
Make sure, especially with mobile use, of your own good stability during
welding.
Do not hold the workpiece in your hands during welding. The workpiece must
be securely fixed during the welding process.
Never wrap the gun lines around parts of your body (e.g. arm) as electric
fields can occur.
If the gun is not put on properly or the gun settings are incorrect, a flash can
occur during welding. Do not look directly into the flash.
The gun carries out lifting movements during the welding process. Do not
hold the gun tight in the area of moving parts.

Operating manual Soyer Bolzenschweißtechnik 15
2.4 Personal protection equipment
The wearing of personal protective equipment is recommended when working with the
stud welding device.
Danger due to missing or incorrect personal protection kit
There is a danger of burns during stud welding, especially due to hot welding spatter.
A danger of blinding can also arise due to the occurrence of strong arcs.
Always wear suitable, closed protective clothing.
The extent of the protective equipment depends on the respective
occurrence and intensity of the welding spatter, arcs and/or noise. This
varies according to the basic material, stud material, stud size and required
welding power.
Heed the instructions concerning protective equipment in the following
overview.
Recommended personal protection equipment
Protective goggles
During welding, welding spatter and a flash occur. Wear
suitable safety goggles with side protection and protect
your eyes with filter protection if necessary.
Protective gloves
During welding, the workpieces and parts of the welding
gun become hot and welding spatter can occur. Wear
suitable, non-combustible, heat-resistant protective
gloves.
Protective clothing
Welding spatter occurs during welding. Wear suitable,
non-combustible and, if necessary, heat-resistant,
protective clothing.
Safety shoes
Welding spatter occurs during welding. Wear suitable,
non-combustible, heat-resistant safety shoes.
Hearing protection
Depending on the welding device and the welding
application, relatively loud welding noises can occur.
Wear suitable hearing protection.

16 Operating manual Soyer Bolzenschweißtechnik
2.5 Intended use of the stud welding device
Pins and threaded studs from M3 –M10 and M12 HZ-1R (M6 to M10 preferred) made
of steel and stainless steel can be welded using the SOYER® BMK-10i stud welding
device.
Special studs or diameters on request.
The stud welding device must only be operated with the welding guns described in
chapter “6.5 Permitted stud welding guns” on page 27.
The stud welding device must be operated within the technical specifications. Only
welding studs from SOYER®(HZ-1 and MF types) must be welded.
The stud welding device supports the following welding processes:
SRM welding (stud welding in a radially symmetrical magnetic field)
Drawn arc stud welding with shielding gas
2.5.1 Incorrect use
Any use other than the intended use of the device is deemed to be non-intended. Any
use other than intended use, unauthorised modification or manipulation of the device
will void the declaration of conformity as well as all warranty claims against the
manufacturer.
2.6 Intended use of the stud welding guns
Pins and threaded studs from M3 to M12 and numerous different weld fasteners
according to DIN EN ISO 13918, made of steel, stainless steel, aluminium and brass,
can be welded with the SOYER® stud welding guns described in this operating manual.
The maximum diameter and type of weldable studs can be limited by the
performance capacity of the stud welding device on which the gun is operated.
Special studs or diameters on request.
The operation of welding guns is only permitted with the stud welding devices described
in the technical data of the gun.
The stud welding gun must be operated within the technical specifications.

Operating manual Soyer Bolzenschweißtechnik 17
2.6.1 Incorrect use
Any use other than the intended use of the welding gun is deemed to be contrary to the
intended use.
Use other than the intended use, unauthorised modification or manipulation of the
device will void the declaration of conformity as well as all warranty claims against the
manufacturer.
Misuse of the welding gun as a tool, e.g. as a hammer for checking the weld quality, is
not permitted.
2.7 Operating company prerequisites
The operator of the device must ensure that the preconditions in this operating manual
are fulfilled for safe operation.
These include, for example, the conditions at the installation site, the official regulations
on requirements for a safe workplace, the training of the operating personnel and
qualified personnel in handling the device if necessary, fulfilment of the prescribed
maintenance work, and monitoring that the device is used in conformity with intended
use.
The operating manual must be stored in the vicinity of the device. The device operating
company must ensure that the device is only used when all protective equipment is
present, active and undamaged.
2.7.1 Prerequisites for personnel
Operating personnel
The personnel responsible for operating the device in normal operation must be familiar
with the device and trained accordingly. They must have read and understood the
operating manual. In addition, they must be capable of eliminating (or minimising as far
as possible) any possible remaining danger to themselves and third parties when
working with the device.
To retain this qualification, the safety training must be repeated annually. In the event
of a fault or if maintenance becomes necessary, consult specially trained qualified
personnel or the manufacturer.
Operators of stud welding equipment must have the expert knowledge for operating,
correctly setting the equipment and for properly carrying out the welding.
If the welders have to be qualified for certification of welding, the DIN EN ISO 14555
and DIN EN ISO 14732 standards must be observed.

18 Operating manual Soyer Bolzenschweißtechnik
Electrical and electronic specialists
The following basically applies: Work on current-carrying elements may only be
performed by qualified electricians. The work must be carried out in line with the
applicable technical rules for electrotechnical devices.
All devices of Soyer Bolzenschweißtechnik GmbH must only be opened by
SOYER®personnel or by personnel authorised by SOYER®.

Operating manual Soyer Bolzenschweißtechnik 19
3 Transport
When transporting the device, make sure it cannot be damaged. It must be protected
against the effects of weather, especially moisture, through suitable packaging.
4 Storage, shutdown
Protect the device against dirt and humidity during storage or shutdown.
Protect the device against unauthorised access by third parties.
5 Disposal
Local environmental guidelines for disposal must be complied with.
Substances that are hazardous to water and the environment must be disposed of in
accordance with legal regulations.
Materials must be separated according to regulations where applicable.

20 Operating manual Soyer Bolzenschweißtechnik
6 Description of the BMK-10i stud welding device
The main elements of the stud welding device and their function are shown and
described in the following.
6.1 Type designation
Designation
Order number
Feature
BMK-10i
PO1366
Mains voltage :
3 x 400 V, 50/60 Hz, 16 AT
6.2 Working method
Pins and threaded studs from M3 –M10 and M12 HZ-1R (M6 to M10 preferred) made
of steel and stainless steel can be welded using the SOYER® BMK-10i stud welding
device.
Only welding studs from SOYER®(HZ-1 and MF types) must be welded.
The BMK-10i working with SRM technology®was specially developed for mobile use.
Thanks to SRM, the BMK-10i mobile welding device enables problem-free welding,
even in constrained positions.
The BMK-10i works on the basis of a compact inverter current source and delivers a
constant welding current up to 600 A with extremely short welding times. The rectified
mains voltage is converted into a high frequency voltage with a frequency of 75 kHz by
an Insulated Gate Bipolar Transistor-based (IGBT-based) inverter. The energy is
transferred by a high frequency transformer and rectified on the output side. As a result
of the high control speed in combination with the integrated SRM welding process of
the BMK-10i, the reproducibility of the welds is increased and the quality of the welding
significantly improved.